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TRACK EQUIPMENT AND TRACK WORKS


Technical Specification

S-90-T-27 (A)


SUPPLY OF GLUED INSULATED RAIL JOINTS
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CONTENTS

1 - GENERAL ............................................................................................. 5
1.1 - Purpose ........................................................................................................... 5
1.2 - General Characteristics ................................................................................ 5
1.3 - Documents Used ............................................................................................ 5
1.4 - Drawings......................................................................................................... 6
1.5 - Manufacturing Site........................................................................................ 6
1.6 - Quality Assurance ......................................................................................... 6
1.6.1 - Control of Manufacturing Quality ................................................................ 6
1.6.2 - Procedure for Quality Assurance ................................................................. 7
2 - MANUFACTURING CONDITIONS ....................................................... 8
2.1 - Materials......................................................................................................... 8
2.1.1 - General ......................................................................................................... 8
2.1.2 - Rails .............................................................................................................. 8
2.1.3 - Fishplates ...................................................................................................... 8
2.1.4 - Bolts ............................................................................................................. 8
2.1.5 - Insulating Inserts and Bushings .................................................................... 9
2.1.6 - Insulating Profile (End-post) ...................................................................... 10
2.1.7 - Glass Cloth ................................................................................................. 10
2.1.8 - Resin Glue .................................................................................................. 11
2.1.9 - Storage ........................................................................................................ 11
2.2 - Preparation of Parts .................................................................................... 11
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2.2.1 - Rails ............................................................................................................ 11
2.2.2 - Metal Parts .................................................................................................. 12
2.2.3 - Insulating Material ..................................................................................... 12
2.2.4 - Preparation of the Glue............................................................................... 12
2.2.5 - Warming the Rails before Gluing .............................................................. 13
2.3 - Assembly of the Glued Joint ....................................................................... 13
2.3.1 - Trial Assembly ........................................................................................... 13
2.3.2 - Final Assembly ........................................................................................... 13
2.3.2.1 - 13
2.3.2.2 - Prepare the Glue (see para. 2.2.4) ........................................................... 13
2.3.2.3 - Apply Glue to Rail or Frog Leg Ends ..................................................... 14
2.3.2.4 - Position the Parts to be assembled and Install the Insulating
End-post Profile ...................................................................................... 14
2.3.2.5 - Apply Glue to the Fishplates ................................................................... 14
2.3.2.6 - Apply Glue to Contact Faces on the Rails or Frog Legs ......................... 15
2.3.2.7 - Install Insulating Bushings in the Fishplates ........................................... 15
2.3.2.8 - Install the Fishplates and Bolts ................................................................ 15
2.3.2.9 - Initially Tighten the Bolts to 40 daN.m Using a Torque Wrench ........... 15
2.3.2.10 - ................................................................................................................ 15
2.3.2.11 - Finish the Joint ...................................................................................... 15
2.3.2.12 - ................................................................................................................ 16
2.4 - Drying ........................................................................................................... 16
2.5 - Handling ....................................................................................................... 16
2.6 - Marks ............................................................................................................ 16
3 - ACCEPTANCE CONDITIONS ............................................................ 17
3.1 - Supervision ................................................................................................... 17
3.2 - Inspections Required ................................................................................... 17
3.3 - Electrical Insulation Test ............................................................................ 17
3.4 - Dimensional Inspection ............................................................................... 18
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3.5 - Tightness Check ........................................................................................... 18
3.6 - Tensile Test .................................................................................................. 18
3.7 - Rejected Joints ............................................................................................. 19
4 - PATENT .............................................................................................. 19
5 - APPENDIX 1 ....................................................................................... 20


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1 - GENERAL

1.1 - Purpose

This specification defines the requirements applicable to the manufacture and
acceptance of glued insulating joints to be integrated into long welded rails or for
use in assembling points.

Glued insulating joints are, in principle, manufactured in plant and delivered on
6m long pieces of rail.


1.2 - General Characteristics

The glued insulating rail joints described in this specification have an insulating
insert between the fishplate and the rail and are of the type used in the Paris
metro. The Contractors have the right to offer other type which should be
approved by the Client.

Each joint comprises:
- two special metal fishplates,
- two insulating inserts,
- six high-strength bolts insulated from the fishplates by special insulating
bushings and washers,
- an insulating profile (end-post) which separates the two rail ends, as shown
in the diagram in Appendix 1.

A synthetic resin-based glue is used. When this is applied, glass cloth is placed
between the fishplate and the insert and between the rail and the insert. The bolts
are heavily tightened before the glue cures.

Glued insulating joints are used in the centre of a 6 to 9m long rail section. The
rail section is cut in its centre and the two cut ends are then joined by a glued
insulating joint.


1.3 - Documents Used

Standards quoted in this specification:
- ISO 4587, 9002 and 9003
- AFNOR NF E 27-701, E 27-702, E 27-711, T 76-107, X 50-132 and 133
- ASTM A-325
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Documents mentioned such as UIC (Union Internationale des Chemins de Fer)
sheets, ISO standards, French standards (NF) or other standards (ASTM, DIN,
etc.) shall be those in force on the date indicated on the specification title page.

If subsequent modifications are issued, the documents indicated shall be replaced
by those in force at the time the order is placed. The Contractor shall keep the
Client informed of such changes, and their implications for the contents of the
specification.


1.4 - Drawings

The drawings provided by the Client show the general arrangements and details,
including dimensions and tolerances.

If he considers making any changes compared to the Client's drawings, the
Contractor shall submit a set of his own manufacturing drawings for approval
before starting any manufacturing work.


1.5 - Manufacturing Site

Glued insulating joints shall mandatorily be prefabricated in factories or a
workshop off the track site. Only certain joints in points may be produced directly
on the track, after prior agreement with the Client.


1.6 - Quality Assurance

1.6.1 - Control of Manufacturing Quality

The Supplier shall develop organization, methods and means allowing it to assure
the quality of production and the control of the supplies destined for the customer.

He shall establish and maintain identifying procedures and traceability of the
products and their components during all stages of production, control and
delivery.

He shall ensure of the traceability of the processes, products or constitutive
elements of the products he sub-contracts, in order to be able to recover easily the
historical of their data, to connect them together and to attribute them with
assurance to the concerned products.
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Traceability mainly concerns:
- the origin of the purchased products, the production processes and the
contractual characteristics of the supplies,
- the transformation and treatment processes,
- the dimendional inspection.

Traceability must allow to find all the products having being subjected to the
same processes of manufacturing and inspection.


1.6.2 - Procedure for Quality Assurance

In place of the direct inspection in the plant by the Client, as defined in the present
specification, the Supplier may ask for profiting by a quality assurance procedure,
specified by standard ISO 9002 relating to the model for quality assurance in
production and installation and by standard ISO 9003 relating to the model for
quality asurance in final inspection and tests, or by their possible enforcements in
the Supplier's country. (Standards NF X 50-132 and 133 for a manufacturing in
France).

This procedure can be implemented only if the Supplier as already obtained a
Quality Assurance Certification and an enabling by an official organization
(Railways or Metro network). In this case, the Supplier shall deliver to the Client
a quality manual, quality plans, and inspection and test plans allowing to make
sure of the application of the conditions of this specification.

The Client, after having examined these documents, carries out an audit at the
Supplier's plant to verify the procedures, the means used for in-process inspection
and the documents giving the results of these tests.

If the Client judges this examination satisfactory, he authorizes the Supplier to
proceed by himself to the inspection of its production. Nevertheless, the Client
reserves itself a right to keep a watch:
- by in-process inspection and testing at random,
- by partial inspection or audits to make sure of the effective application of the
quality plans and of their efficiency, in particular after a long-lasting
interruption of manufacturing.

In case of sigificant, and unrectified, deviations with regard to the approved
procedures, the Client may suspend the quality assurance procedure and apply the
direct inspection defined in the present specification.
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2 - MANUFACTURING CONDITIONS

2.1 - Materials

2.1.1 - General

The materials used in glued insulating rail joints shall comply with the following
requirements, which may modify or extend those indicated on the Client's
drawings.

The Contractor shall supply the Client or his representative with test certificates to
guarantee the compliance of the materials before starting any manufacturing work.


2.1.2 - Rails

These shall be produced from grade 900 A steel as per technical specification S-
90-T-1(A).


2.1.3 - Fishplates

These are 6-hole fishplates with a special profile which allows full contact to be
obtained over the face after allowing for the thickness of the insert. Fishplates
shall be machined, to the required shapes and tolerances, from rolled steel or a forged
steel blank as per technical specification S-90-T-19 (A) concerning steel fishplates.


2.1.4 - Bolts

The used bolts, called structural bolts for controlled tightening, shall be high-strength
bolts designed to guarantee a minimum clamping load on the parts assembled.

The screws, nuts and washers shall possess the following mechanical properties:

Screws:
- 0.1% elasticity limit (yield point): 900 N/mm

- tensile strength: 1 000 R 1250 N/mm

- elongation at failure: A% 8
- resilience KCV (impact) at -20C: 35 J/cm

- Vickers hardness HV/30: 300 to 380
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Nuts:
- Vickers hardness HV/30: 300
- proof stress: 1000 N/mm

Washers
Vickers hardness HV/30: 300 to 360.

If produced in France, these components shall satisfy the requirements of
standards NF E 27-701, E 27-702 and E 27-711 with a 10.9 quality class for bolts
and 10 for nuts.

If parts are produced to American standards, bolts shall satisfy the requirements of
the ASTM "High-strength bolts for structural steel joints" standard A325. As far
as possible, the qualities and grades shall be selected to comply with the standards
mentioned above.

In any other case, the Contractor shall either produce the parts to comply with the
above requirement or suggest the application of other standards which satisfy
equivalent requirements, together with all necessary justification, to the Client for
approval.

The glued insulating joint contractor shall be responsible for ensuring the quality
of the bolts; these operations shall be carried out as required by the selected
standard.

However, if agreed by the Client, the contractor may provide a certificate from the
bolt contractor, containing the results of all the tests required by the standard and
guaranteeing the origin of the parts.

The bolts and nuts shall mandatorily carry all marks required by the standard. No
protective treatment shall be applied but the threads shall be lubricated prior to
delivery.


2.1.5 - Insulating Inserts and Bushings

The insulating inserts and bushings shall be manufactured as per specification S-
90-T-25 (A) concerning the supply of small insulating pieces except for
dimensional tolerances which shall be as following if not indicated on the
drawings provided by the Client.

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Dimensional tolerances:

- on insulating inserts:
. thickness: +0.2 ; -0.1 mm
. hole diameter: 0.5 mm
. hole positions: 0.5 mm.

- bushings:
. outside diameter: -0.1 ; -0.3 mm
. inside diameter: 0.2 mm.

- washers:
.outside diameter: 1 mm
. inside diameter: 0.5 mm
. thickness: 0.3 mm.


2.1.6 - Insulating Profile (End-post)

The end-post, with a thin protruding section, shall be manufactured as per
specification S-90-T-26 (A) concerning the supply of plastic end-posts except that
the material shall be polyamide 11.


2.1.7 - Glass Cloth

The purpose of the glass cloth is to retain a certain quantity of glue when the bolts
are tightened. A large-mesh cloth, approx. 0.4 mm thick, shall be used. All
"ensimage" shall be removed from the cloth to ensure good adhesion of the epoxy
resin. "Ensimage" is a coating applied to the glass threads to facilitate their use as
a textile fibre but it is generally incompatible with the resins used.

The cloth can be ordered as strips of appropriate width (the developed width of
the glued face of the insulating insert plus approx. 15 mm). These strips shall then
be cut to a suitable length (the length of the insulating insert plus 15 mm) and the
holes for the bolts shall be punched in them.


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2.1.8 - Resin Glue

The glue shall be prepared by mixing an epoxy resin and a hardener. It shall have
a shear strength of at least 20 daN/mm

, measured as described in ISO standard

4587 or its possible applicating standard in force in the Contractor's country
(standard NF T-76-107 for manufacture in France).

On the date this specification was issued, two glues have already been approved:
- Metalon E-2-02 by Henkel
- grade 21 720 by UDD-FIM (Delle - 90100, France).


2.1.9 - Storage

The material required for the joints (fishplates, bolts, glue, insulating materials,
etc.) shall be stored in a closed room, protected against bad weather. The glue
shall be stored at a temperature above 10C.


2.2 - Preparation of Parts

2.2.1 - Rails

Glued insulating joints manufactured in plant are delivered in a 6m long rail.

The section of rail which is to include the glued insulating joint in its centre shall
only be cut using a power saw or a single pass with a disc. The ends alongside the
cut shall then be drilled as shown on the drawings.

They shall be carefully cleaned and any protrusions, traces of corrosion, grease,
and in general terms, any residues which could jeopardize the adhesion of the glue
shall be removed. These cleaning operations shall apply to all surfaces in contact
with the fishplates, webs and ends, over a length of at least 0.50m.

The areas shall be ground down to white metal (no other method shall be used)
and then degreased with tricholorethylene. The inside of the holes shall also be
cleaned.


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2.2.2 - Metal Parts

The surfaces of the fishplates and the holes they contain shall be very carefully
cleaned in the same way as the rails.

These parts shall be cleaned in at least two phases:
- mechanical cleaning: the recommended method is shot-blasting,
- chemical cleaning: all shot-blasted surfaces shall be cleaned with a solvent to
remove any dust, grease, etc.

All precautions shall be taken to ensure that the clean parts are not exposed to
humidity and are protected against any contamination. In particular, it is important
not to touch these surfaces with the hands.

In general, it is advisable to clean these parts as shortly as possible before
assembling the joint. Bolts shall not be degreased.


2.2.3 - Insulating Material

The insulating materials shall be delivered in packing specially designed to avoid
any contamination or contact with humidity.

Before installation, any traces of wax or varnish which could jeopardize adhesion
of the glue shall be removed.


2.2.4 - Preparation of the Glue

The resin begins curing as soon as it is mixed with the hardener. The speed of the
reaction depends on the ambient temperature. Consequently, the resin-hardener
mixture shall only be prepared once the joint is ready for gluing.

The glue consists of two components, a basic resin and a hardener. Equal
proportions by weight shall be carefully mixed until a uniform paste is obtained.

The components shall be weighed-out as accurately as possible.

Complete cans shall always be mixed by pouring the resin into the can containing
the hardener. It is forbidden to assemble glued insulating joints, or to store the
joints while the glue is curing, in rooms with an ambient temperature below 10.
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2.2.5 - Warming the Rails before Gluing

If the temperature of the room in which the glued joints are assembled is below
20, the rails shall be warmed to 25 to 30 before assembling the joint (a higher
temperature will cause the glue to run).


2.3 - Assembly of the Glued J oint

2.3.1 - Trial Assembly

A trial assembly is mandatory for glued insulating joints on points frogs, where
the joint links a rolled section to a cast component. This operation is not required
on joints in normal rail or stock rail.

The "trial assembly" consists in assembling all components of the joint without
applying the glue. In this case, the bolts shall only be tightened to 40 daN.m.

The trial assembly is used to locate any alignment faults in the running and
guidance surfaces of the rail head. These faults shall then be corrected by grinding
or bending before final assembly of the joint.

After adjustment of the joint and before final assembly, check that none of the
glued parts has been contaminated (generally by dust, grease or water).


2.3.2 - Final Assembly

The procedure shall be as follows:

2.3.2.1 -

Clean any parts which have been handled since the preparatory operation as
described in para. 2.2 with trichlorethylene.


2.3.2.2 - Prepare the Glue (see para. 2.2.4)

Once the glue has been prepared, the operations described in 2.3.2.3 to 2.3.2.9
shall be completed in less than 40 minutes.


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2.3.2.3 - Apply Glue to Rail or Frog Leg Ends

A coat of glue shall be applied to all areas of the rails which will be in contact
with the fishplates before the fishplates are installed.

A thin coat of glue shall also be applied to the two rail ends in contact with the
insulating end-posts. Once the end-post is installed, a bead of glue shall be applied
under the flange, on either side of the protruding part of the end-post to form a rib.

The end-post shall be positioned such that the vertical face of the railhead section
lies on the side where the nuts will be at the rail upper face edge.


2.3.2.4 - Position the Parts to be assembled and I nstall the I nsulating
End-post Profile

Glued insulating joints in normal track shall, in addition, be arranged such that the
rails are drawn together longitudinally after the end-post is in position. This shall
be done using a crank jack (approx. 100 daN.m) and is intended to facilitate
assembly of the joint.


2.3.2.5 - Apply Glue to the Fishplates

Fishplates shall be placed on chocks approx. 10 cm high, with the faces to be
glued uppermost. Raising the fishplates in this way makes it easier to apply glue
to the edges of the fishplate mating surfaces and to transport the fishplate to the
joint position after application of the glue. Special pins can be used to transport
the fishplates thus coated with glue.

The following shall be applied, in sequence, to the inner face and the two mating
surfaces of the fishplate which will be in contact with the rail:
- a thin coat of glue, spread with a spatula,
- a glass cloth,
- a thin coat of glue applied over the cloth,
- a prefabricated insulating insert,
- a thin coat of glue applied to the insert,
- a glass cloth.

The glass cloth shall be applied carefully and slightly taut to avoid folds; the holes
punched for the bolts shall align perfectly with those in the fishplate and the
insulating insert to avoid any difficulties in inserting the bolts.
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A special application roller shall be used to ensure the glue penetrates into the
glass cloth.

Fishplates for glued joints are not symmetrical; care must, therefore, be taken in
positioning the fishplates correctly, after application of the glue, before placing
them on the rail.


2.3.2.6 - Apply Glue to Contact Faces on the Rails or Frog Legs


2.3.2.7 - I nstall I nsulating Bushings in the Fishplates


2.3.2.8 - I nstall the Fishplates and Bolts

Bolts shall be installed in the as-delivered condition, i.e. with the surfaces
lubricated.


2.3.2.9 - I nitially Tighten the Bolts to 40 daN.m Using a Torque
Wrench


2.3.2.10 -

Approx. 20 minutes later, finally tighten the bolts, progressively, up to 75 daN.m
(for a 22 mm dia. bolt)

To ensure effective clamping of the complete fishplate length, the bolts shall be
tightened progressively, starting with the central bolts at each step, followed by
the end bolts and finally the intermediate bolts.


2.3.2.11 - Finish the J oint

The following operations shall be carried out to finish the joint:
- cut any glass cloth which protrudes beyond the fishplates,
- lightly sand the end-post edges using a flexible disc,
- remove any excess glue ejected when the bolts are tightened and form glue
chamfers at the joint line between the fishplate and the flange, fishplate and
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web and fishplate and railhead.
Avoid forming hollows between the fishplate and rail; on the contrary an
insulating rib should be left.

- apply drops of glue to the nuts to prevent loosening.


2.3.2.12 -

Once the joint is completely dry, as defined in para. 2.4, grind the rail top surface
and the guide face if necessary.


2.4 - Drying

After completion of the operations described in 2.3.2.1 to 2.3.2.12, carry out the
drying of the joint:
- either in a hangar, at an ambient temperature above 20C, for 24 hours,
- or using radiant panels to heat the glued joint to 80C for 4 hours.

The temperature shall be checked at the beginning of the drying process using a
thermometer placed close to the fishplates.


2.5 - Handling

Once the glued insulated joint has been completed, the rail shall not be handled
throughout the drying period.

The drying area shall ensure that the joint remains perfectly straight in all
directions throughout drying.

Once dry, rails with glued joints shall only be handled using a very long lifting
beam to minimize the bending loads at the joint.


2.6 - Marks

An aluminium identification plate shall be glued to the rail web at approx. 1.50 m
from the centre line of each glued insulating joint. This plate shall carry the
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following letters and numbers to identify the joint:
- a letter defining the type of glue used, for example M for Metallon,
- a manufacturing serial number,
- an indication of the three month period (quarter-year) and the last two figures
of the year in which the joint was produced,
- a symbol indicating the grade of the rail steel.



3 - ACCEPTANCE CONDITIONS

3.1 - Supervision

The Client's representatives shall have free access to the worksite or parts of the
contractor's factories producing the joints at any time of day throughout the entire
manufacturing period. They shall be able to carry out any checks they consider
necessary. All tests shall be carried out in the contractor's laboratories at his cost.


3.2 - Inspections Required

The following tests and inspections shall be carried out on completed glued
insulated joints:
- electrical insulation test: all joints,
- dimensional inspection: all joints,
- tightness check: all joints,
- tensile test: one joint per batch of 50 parts and at least one test if less than 50
parts are manufactured.


3.3 - Electrical Insulation Test

The electrical insulation shall be checked using a magneto megohmmeter with an
off-load voltage of 500 volts.

The electrical resistance of the joint measured:
- across the two rail ends (or frog leg end),
- across the rail ends (or frog leg) and each fishplate,
- across the two fishplates,
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shall be higher than 10 000 ohms, regardless of the ambient relative humidity.

The contacts shall be applied to clean, uncorroded metal parts.

Any joint which does not meet the above requirements shall be rejected.

The provisions of this test should be approved by Power Supply and Signalling
contractors.


3.4 - Dimensional Inspection

The assembly tolerances applicable to glued insulating joints are:
- bow measured over a 1 metre length of the rail top face: 0.2 mm,
- bow measured over a 1 metre length of the guide face: 0.5 mm.

These values shall be checked on each joint using straight edges and feeler
gauges.

Any joint not within the above tolerances shall be rejected.

The provisions of this test should be approved by power and signalling
contractors.


3.5 - Tightness Check

The tightness check involves applying a tightening torque of 70 daN.m to the
bolts in the joint assembly using a torque wrench.

The nut shall not turn.

Any joint which does not satisfy this requirement shall be rejected.


3.6 - Tensile Test

The tensile test involves progressively applying a load up to 7x10
N
(70 tons) to
the joint using a rail puller. The puller shall be provided by the contractor.

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The joint shall withstand this load with no damage and the residual elongation,
measured after release of the load, shall be less than 0.10 mm.
If this requirement is satisfied, the batch shall be accepted.

If the elongation exceeds 0.10 mm, the joint shall be rejected and a confirmatory
test shall be carried out on three other joints in the batch.

If the confirmatory test is satisfactory, the batch shall be accepted.

If the confirmatory test is not satisfactory, each joint shall be individually tested
and rejected if the result is not satisfactory.


3.7 - Rejected J oints

If he wishes, the contractor may disassemble rejected joints, using a torch, to
recover the rail sections and/or points components.



4 - PATENT

The contractor shall pay the patent rights for any patents used and shall indemnify
the Client against any claims for the use of such patents.
TRACK D1-L3-TK-T1
Ref : S-90-T-27.DOC
Edition 3 Oct. 2002
GREATER CAIRO METRO LINE N 3
DESIGN STAGE PHASE 1
Track Technical Specifications
D1-L3-TK-T1
Page 20/20

5 - APPENDIX 1
TECHNICAL SPECIFICATION
FOR THE SUPPLY OF GLUED INSULATING JOINTS
EXPLODED VIEW



Constituent parts of a glued insulating joint (5 holes):
- 2 steel fishplates
- 5 high resistance bolts with steel washers
- 6 insulating bushings
- 2 insulating inserts
- 4 glass cloths (0.4mm thick)
- 12 insulating washers
- 1 insulating profile
- epoxy glue with synthetic resin base